Boiler Control Solution

Boiler Control Solution

Instruments and Solution for
Automatic Boiler Control

LF3BUSS02-00EN

www.yokogawa.com
Best Solution for Automatic Boiler C
Sensors and controllers for the efficiency and environmental performance

Essential Equipments for Industries Drum Level Measurement

Boilers are used in a broad range of indus-
tries such as electric power, pharmaceuti-
cals, chemicals, ceramics, and paper and
pulp. Amid the rising energy costs, tighten- Overview and
ing environmental regulations, and increas- Problems
ing awareness of safety as of late, the needs • Drum level
for high efficiency operation, low emission measurement
operation, and safe and stable operation of • High stability
boilers are growing. measurement
Increasing Efficiency and Lowering required under large
static pressure
Emissions of Boilers change
In order to ensure the air and fuel are com- EJX EJA
busted at an optimal ratio, the waste of fuel
is eliminated, and the exhaust gas is
cleaned, real-time monitoring of the oxygen Solution Benefits
concentration of combustion gases is re- • Field proven silicon resonant • Long term high
quired. Equipped with an oxygen sensor sensor guarantees long term stability measurement
unit with a longer life span, the Zirconia stability is realized under
Oxygen Analyzer ZR series are capable of EJA: 0.1 % of URL 5 years actual plant conditions
measuring an oxygen concentration with
high reliability. The Stack Gas Analyzer
EJX: 0.1 % of URL 10 years
SG700 monitors exhaust gas components Under all conditions
such as NO x, SO 2, and CO 2 in order to en- (temperature, static and over
sure low emission operation. pressures)

Safe and Stable Operation

A single-loop controller can be used to prop-
erly distribute control functionality. Offering
the advantages of flexibility of building dis-
tributed control systems, simple mainte-
nance, compatibility with conventional sys-
tems, and the like, the YS1000 Series of
Single-loop Controllers are ideal for safe and
stable operation at low costs.
Monitoring the drum level and steam
flow rate in accurate at any conditions
In order to ensure highly efficient and safely
operated boilers, it is also indispensable to
accurately monitor the drum level and
steam flow rate. The EJA and EJX Series of
Differential Pressure Transmitters are capa-
ble of measuring the drum level with high
stability even in actual applications at high
temperatures and high pressures. The DY
Series MV TYPE of Vortex Flowmeters with
a simple construction employ a built-in sen-
sor to measure the steam mass flow with
high reliability.
Why Buy Yokogawa?
Yokogawa offers a wide variety of sensors
and controllers that are used to monitor and
operate boilers, and contributes to increas-
ing the efficiency and environmental perfor-
mance of boilers, as well as ensuring their
safe and stable operation.
We want you to explore Yokogawa's sen-
sors and controllers in order to increase the
efficiency and environmental performance
of your boilers, and ensure their safe and
stable operation.
Combustion Control
Overview and Problems
• Perform safe and stable control at
low cost
• Lower levels of emission output
Solution
• Simple programming by Function
Block wiring method
• Cascade primary direct control
- Stable level control when boiler
is started
• Cross limit control calculation
YS1000
- Air and flow are calculated so
that air flow always exceed fuel
flow to prevent incomplete
combustion and explosion
• Feed forward control
- The main stream pressure and
feed water level are controlled
quickly in response to changes
in the main stream flow
Benefits
• Reduced debugging time
• Improvement of the reliability of
programs
• Safe and stable control at low
cost
Control
Steam Flow Measurement
Overview and Problems
• Flow measurement for utility steam
• Conventional orifice flowmeter requires complicated, high cost installation and is not
accurate
Solution
• Inline flowmeter
• Built-in temperature sensor, Digital YEWFLO MV type
• Steam mass flow measurement without additional temperature sensor/transmitter and
flow computer
• Accuracy 2 % of reading
Benefits
• Low installation and operational costs
DY MV TYPE • Safety operation to reduce leakage points
• Save energy by accurate measurement

(Boiler master)
Main steam pressure control
Feed water level control
Fx
PV1 Cascade
FF
PRD control
PV2
PV FF

Steam

Main Main
steam steam
Drum pressure flow
level Feed water
SV SV
Air flow control Fuel flow control

Exhaust
gas oxygen Fx
concentration
PV PV control

SV
Fuel oil Exhaust
Gas Monitor
Fuel oil flow

Air flow Oxygen Exhaust

concentration gas

Air
 E
lectrolyzer

S
olution

Combustion Control
Overview and Problems
• O2 control for optimum combustion
• Short sensor life by clogging
Solution
• Long life sensor with molecular bonding and special coating
• Cell life prediction
Benefits
ZR402G • Fuel cost reduction
• Preventive maintenance
ZR22G/S • Protect the environment, CO2 reduction

Combustion Control
Overview and Problems
• O2 control for optimum combustion of large-sized combustion equipment
• High installation cost for multipoint measurement
Solution
• Maximum 8 detectors can be connected to one AV550G converter
• O2 measurement of
multiple points, individual
concentration and average values
Benefits
• Accurate control by multipoint Handles input of up to
8 oxygen detectors
measurement
• Installation cost reduction C02

3.0%02 2.8%02
2.4%02
H20 H20
02
3.0%02 02 3.0%02
2.6%02
C02 C02
02 Averaging Converter
AV550G
Large combusion facilities (Image)

Exhaust Gas Analysis

Overview and Problems
• Air pollution control by continuous emissions monitoring
• High maintenance frequency
Solution
• Simultaneous measurement of up to five components, NOx, SO2,
CO, CO2, O2
• Sample conditioning system designed to reduce maintenance
• No moving parts in the sensor
Benefits
• Stable, long-term measurement
SG700
• High accuracy to suit the environmental regulations
 Technologies Commit Users’ Benefits

Our Goal
Our shared goal is customer satisfaction through operational excellence.
Yokogawa has brought true innovations to industry. We are committed to ensuring accuracy,
reliability, and safety of your production system throughout your business life cycle. Our com-
prehensive solutions and expertise help you achieve more results with less total costs of own-
ership. Below key technologies shall aim for your operational excellence.

EJA/EJX Silicone Resonant Sensor YS1000 Dual CPU

By micro-machining the CPU W i t h d u a l - C P U c o n-
resonators directly within struction, manual control
the single crystal silicon capability and display
Gate Array
material we are able to continues even if an ab-
derive the maximum ben- normality occurs on one
efits from the elasticity of of the CPUs. If controller
CPU
the single crystal silicon self-diagnostics detects
material while enhancing a control circuit failure,
sensitivity and repeatability. The properties of the controller can sus-
the resonators remain constant over time. pend analog/digital output, switch to manual
This makes DPharp the ideal pressure sensor mode and allow manual control by operator.
for harsh industrial automation environments.
DPharp delivers stability, repeatability and re-
liability that you can rely on.

Zirconia Oxygen Analyzers

(+) Preference gas
contact part - Get a long service life
and stable operation
with a Zirconia sen-
DY Key Technology Ceramic
Conductor sor
-Spectral Signal Processing (SSP)- (+) Electrode on
reference side
(-) Sample gas contact part - sensor replacement
Spectral Signal Processing (SSP) technology Bolt Calibration Metal O-ring is easy
gas pipe

is built into the powerful electronics of the dig-

italYEWFLO vortex flowmeter, enabling new • A molecular bonding
A
functions. SSP analyses the fluid conditions method completes in- D
O
inside the digitalYEWFLO vortex flowmeter Cell
stallation of platinum
Screen
and uses the data to automatically select the Bracket electrodes, and its in-
optimum adjustment for an application, pro- herent connection pre-
viding features never seen before in vortex vents separation of
flowmeters. platinum from the Zirconia element.
• A lead-less electrode design eliminates elec-
trical disconnection.
Input signal Frequency analysis (SSP function)
• Special coating protects the platinum and
Judged to be Removed
prevents the sensors from deteriorating.
noise
Judged to be
Output
• No special tool is required for cell replace-
vortex signal
Judged to be
Removed
ment.
noise
 For Your Operational Excellence
Temperature Transmitter Direct In Situ Zirconia Oxygen Analyzers
ZR402G
YTA Series ZR402/ZR202
• High resolution, high stability and • Measurement with probe directly
high versatility inserted into furnace or boiler
ZR22G/S
• Dual compartment housing for • Integrated and separate types available.
harsh environments • Also can be used as a high
temperature humidity analyzer
• SIL2 safety as standard feature ZR202G/S
• Fully field-repairable probe
• Fieldbus communication capability • HART communication
• Explosion proof (FM, CSA, ATEX)
(ZR22S, ZR202S)

Pressure Transmitter Averaging Converter

DPharp EJA/EJX Series AV550G
• Best installed performance • Capable of accepting inputs from
• Compact and rugged design up to 8 oxygen detectors and 8
individual outputs are available
• Multi-Sensing digital sensor
• Averaging of multiple point
• SIL2 as standard (EJX) oxygen measurements is ideally
• Fieldbus communication capability suited for combustion control

DigitalYEWFLO Vortex Flowmeters Stack Gas Analyzing System

• Best-in-class accuracy SG700
• Superior stability though the unique
digital electronics SSP technology • A complete self standing cabinet
including IR400 infra-red analyzer
• Complete range for temperature and the sample conditioning
and pressure system
• Multivariable availability with • Simultaneous measurement of up
optional temperature sensor to five components, NOx, SO2,
• Fieldbus communication capability CO, CO2, O2

Single Loop Controller

YS1000 Series
• Two programming method
• High reliability
• Compact and light weight
• Expandable I/O
• Compatible with YS170 and
SLPC

ADMAG AXF and DAQMASTER are registered trademark of Yokogawa Electric Corporation.
DPharp is a trademark of Yokogawa Electric Corporation. Ethernet is a registered trademark of Xerox Corporation.
Other company names and product names appearing in this document are registered trademarks or trademarks of their respective holders.

YOKOGAWA ELECTRIC CORPORATION Phone: (81)-422-52-6329, Fax: (81)-422-52-6619

YOKOGAWA CORPORATION OF AMERICA Phone: 800-888-6400, Fax: (1)-770-251-6427
YOKOGAWA EUROPE B.V. Phone: (31)-88-4641000, Fax: (31)-88-4641111
YOKOGAWA ENGINEERING ASIA PTE. LTD. Phone: (65)-62419933, Fax: (65)-62412606 Printed in Japan, 904(KP) [Ed : 01/b]

Subject to change without notice.

All Rights Reserved, Copyright© 2008, Yokogawa Electric Corporation.